APQP Training November 2011.ppt

When PPAP is required is defined in Section I.3 of the PPAP Manual (starting on page 11) - customer notification required. Default level for raw material is 4 PPAP package forms, checklists, charts, capability analysis, measurement analysis included in PPAPall in an Electronic Format Discussion: Analysis and use of data. Corrective Action Continuous Improvement From the APQP and Control Plan manual, and from our discussion thus far, we know that these four ‘documents’ are required. We should also by now understand that these can be looked at as ‘elements’ where each is not a discrete document. When looking at one of these required ‘documents’ in terms of it being an element (as opposed to a discrete document) we have to look at each and determine what the specific requirements are for it. As with the control plan example on the next slide, there is a ‘minimum’ content required for each element. This diagram is another way to illustrate several developmental / critical paths of the main documentation requirements. As we discussed earlier, the APQP and Control Plan manual represents these as different, discrete documents. However, one should look at them as ‘element’ requirements. In the Ford DCP the process control plan ‘element’ is in the same document as the process FMEA ‘element’. None the less, the critical path rules still hold true. For example, in the DCP the control plan ‘part’ cannot be completed until the FMEA ‘part’ is completed. As we started to look at on the previous page, it is evident that the process flow diagram be ‘completed’ early. This is because it serves to identify all processes involved from which internal critical (special, whatever) characteristics are derived. I have only seen a couple of companies which got through a QS audit with NO internal critical / special characteristic. The above illustration shows the internal links in these documents which key each to the other. Note that the design FMEA does not have an internal link